JPH09252886A - Mattress - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mattress having a hygroscopic property and comfortable using feeling and easy to recycle. SOLUTION: The cotton padding of this mattress is constituted of rolled cotton of polyester fibers and hand cotton of polyester fibers. The rolled cotton contains composite fibers A composed of at least 15-50wt.% of and 50-15wt.% of a polyester R2 component 2, and it has the hygroscopic percent of 2% or above after it is left for 24hr in the atmosphere of 30 deg.C×90%RH. At least a part between low-melting point fibers B and between the low-melting point fibers B and other fibers C is stuck in the hard cotton. The cotton padding fibers have a good thread forming property when they are manufactured, this mattress has comfortable using feeling, and it can be easily recycled.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mattress and the like, and more particularly, to a polyester mattress of a stuffed cotton of the mattress to have hygroscopicity to improve the comfort of use of the products for use and to provide the mattress. The purpose of the present invention is to provide a futon that can be easily recycled by constructing the whole with polyester fibers.

[0002]

2. Description of the Related Art Conventionally, polyester-based synthetic fiber stuffed cotton has been used in many products for the above-mentioned purpose because of its excellent bulkiness, light weight and excellent heat retention. This polyester synthetic fiber stuffed cotton is made to have three-dimensional crimp by composite spinning or asymmetric cooling to be excellent in bulkiness, or, for example, as described in Japanese Patent Publication No. 6-51076, the forward direction. A type of three-dimensional crimped fiber and a reversal type three-dimensional crimped fiber can be used in combination to make it excellent in bulkiness under no load or under load, have a deformed cross section such as a hollow fiber, fiber fineness, fiber length or oil agent. It is also seen that the bulkiness and texture have been improved by optimizing. Further, in order to obtain a soft texture by adding a silicone resin, for example, Japanese Patent Publication No. 52-28426 and Japanese Utility Model Publication No. 53-53.
The inventions disclosed in Japanese Patent No. 53, Japanese Patent Publication No. 4-34435, etc. are disclosed. However, since all of these polyester synthetic fiber stuffed cotton have no hygroscopicity and tend to be stuffy, they are used as stuffed cotton for winter or compound, and are hardly used for summer.
It is desired to eliminate this drawback and develop a cotton for all seasons including summer.

On the other hand, from the two needs of environmental protection of the earth and efficient use of resources, the problem of processing and reusing industrial waste and general household waste is becoming more and more important, and in many fields. , Many people are interested. However, in the field of futons, most used futons have been landfilled so far, and recycling technology is still in the development stage.

Conventionally, the proposed recycling techniques for textile products are roughly classified into the following three types.

The first is thermal recycling. In this method, products are cut into appropriate forms, burned, and reused as in-house power generation and various types of heat energy. However, this method is not preferable from the viewpoint of resource reuse.

The second is material recycling. This method differs from the following chemical recycling in that it is pelletized physically and mechanically. When this recycled pellet is reused, it is divided into two cases. One is to develop a product as a new material in consideration of the fact that various materials are mixed, such as flower beds, pots for bonsai, and decorative piles for sidewalks. The other is disclosed in Japanese Unexamined Patent Publication Nos. Hei 5-212935 and Hei 6-123052.
In this case, it is composed of 0% of the same material, collected, pelletized, melted and reused.

The third is chemical recycling. The chemical recycling that best matches the basic concept of recycling is chemical recycling, which collects products, decomposes them, and returns them to their original raw materials. However, in general, few fiber products are manufactured with a single material, and the material composition is diverse, so it takes some time to develop an economical depolymerization system. Means for solving this problem, for example, in the case of carpet products, is described in Japanese Patent Application Laid-Open No. 5-117441. As an auxiliary means for improving the efficiency of depolymerization, the carpet is fragmented, separated into small pieces containing nylon 6 which is a pile material and other small pieces by a separator, and the small pieces containing nylon 6 are supplied to a depolymerization system. This is a method of recovering ε-caprolactam as a raw material. However, even if the carpet is cut into small pieces and separated by mechanical means, for example, due to a difference in specific gravity due to a cyclone, etc., the small pieces containing nylon 6 still contain polyester spunbond of tufting base cloth and chloride of the sealing layer and backing layer. Since it contains vinyl, neoprene rubber, polyethylene, etc., the difficulty of depolymerization purification has never been solved.

That is, a comforter which is comfortable to use and easy to recycle is not disclosed with hygroscopic polyester fiber stuffed cotton.

[0009]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a mattress that has a hygroscopic and comfortable feel and is easy to recycle.

[0010]

The mattress of the present invention has the following constitution in order to solve the above-mentioned problems.

That is, the cot is a mattress composed of a polyester fiber wound cotton and a polyester fiber hard cotton, and the wound cotton includes at least 15 to 50% by weight of the polyether ester amide R1 component and polyester R2.
A composite fiber A containing 50 to 15% by weight of components,
And, the moisture absorption rate after standing for 24 hours in an atmosphere of 30 ° C. × 90% RH is 2% or more, and the hard cotton is at least between the low melting point fibers B and between the low melting point fibers B and the other fibers C. It is a mattress that is partially bonded.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The mattress of the present invention will be described in detail below with reference to the accompanying drawings while referring to the drawings.

The mattress of the present invention uses a hygroscopic polyester fiber as at least a wound cotton, and imparts comfort to use due to moisture absorption, and at the same time, the mattress of the mattress is made of a polyester material. It is a mattress made of fibers that is easy to recycle.

The structure of the polyester fiber stuffed cotton having a hygroscopic property is a composite of a polyetheresteramide R1 component and a polyester R2 component, and the polyetheresteramide R1 component has a high hygroscopic property. 1, FIG. 2 and FIG. 3 are schematic cross-sectional views of an embodiment of the conjugate fiber of the present invention, FIG. 1 shows an example in which R1 and R2 are concentric core-sheath, and FIG. This is an example of an elliptical hollow shape in which R2 is blended, and FIG. 3 is an example showing a trilobal hollow shape in which R1 and R2 are composited in three layers.

The polyetheresteramide R1 component of the cotton stuffing of the present invention is a hygroscopic component, and a block copolymer having an ether bond, an ester bond and an amide bond in the same molecular chain can be used. For example, lactam,
One or more polyamide-forming components (a) selected from aminocarboxylic acids, salts of diamines and dicarboxylic acids and a polyetherester-forming component (b) consisting of dicarboxylic acids and poly (alkylene oxide) glycols A block copolymer polymer or the like obtained by a polycondensation reaction can be used.

As the polyamide-forming component (a) of the polyether ester amide of the present invention, caprolactam,
Lactams such as enanthlactam, dodecanolactam and undecanolactam, ω-aminocarboxylic acids such as aminocaproic acid, 11-aminoundecanoic acid and 12-aminododecanoic acid, precursors of nylon 66, nylon 610, nylon 612, etc. The diamine-dicarboxylic nylon salt can be used, and these can be used alone or in combination of two or more. Preferred polyamide-forming components are ε-caprolactam, a nylon 66 salt.

On the other hand, a dicarboxylic acid having 4 to 20 carbon atoms and poly (alkylene oxide) glycol can be used as the polyether ester component (b) constituting the soft segment of the polyether ester amide. As the dicarboxylic acid having 4 to 20 carbon atoms, succinic acid,
Aliphatic dicarboxylic acids such as glutaric acid, adipic acid, vimelic acid, suberic acid, sebacic acid, dodecadiic acid, etc., aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid An alicyclic dicarboxylic acid such as an acid can be used, and one kind or a mixture of two or more kinds can be used.
Preferred dicarboxylic acids are adipic acid, sebacic acid, dodecadic acid, terephthalic acid, isophthalic acid.

As the poly (alkylene oxide) glycol, polyethylene glycol, poly (1,2)
-And 1,3-propylene oxide) glycol, poly (tetramethylene oxide) glycol, poly (hexamethylene oxide) glycol, random or block copolymerization of ethylene oxide and propylene oxide or tetrahydrofuran, and the like can be used. The number average molecular weight of the poly (alkylene oxide) glycol is preferably 300 to 10,000, more preferably 500.
It can be used in the range of up to 4000.

The polyether ester amide block copolymer of the present invention is obtained by polycondensing the above-mentioned polyamide-forming component (a) and polyether ester-forming component (b). As an industrially preferable method, there is a method in which (a) and (b) are heated and polycondensed under reduced pressure. In this case, in order to obtain a polymer having a high degree of polymerization and less coloring, for example, antimony oxide, titanium It is preferable to add an acid ester or the like as a polycondensation catalyst, and add phosphoric acid, a phosphoric acid ester or the like as a coloring inhibitor. The weight ratio of (a) and (b) in the polyether ester amide is 99 /
1 to 5/90 is preferable, and more preferably 80/20 to
It can be effectively used in the range of 10/90.

As described above, the thermoplastic polymer constituting the hygroscopic layer of each of the polyester-based fiber-stuffed cotton fibers may be composed of only the polyether ester amide as described above. It may be composed of a blend component of the polyether ester amide R1 and the polyester R2 as long as the spinnability is not impaired.

The polymer may be blended either in a state in which the individual polymers are mixed with each other to be homogeneous, or in a state in which the individual polymers coexist without being completely mixed. In the present invention, the states of the polymers are not particularly limited, but from the viewpoint of moisture absorption efficiency, it is preferable that the polyether ester amide R1 component and the polyester R2 component are present separately in one fiber. .

Polyester R2 of stuffed cotton in the present invention
Although the component is not particularly limited, for example, terephthalic acid,
A linear polyester such as polyethylene terephthalate, polybutylene terephthalate, or polyethylene 2,6-naphthalate containing 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component and ethylene glycol or tetramethylene glycol as a main glycol component. Can be used. Of these, polyethylene terephthalate (normal polyester) is preferably used from the viewpoint of increasing the strength of the fiber of the present invention.

Further, the polyether ester amide R1 component and the polyester R are used as the thermoplastic polymer which constitutes the moisture absorbing layer of each of the fibers of the polyester fiber stuffed cotton.
As the polyester R2 component to be blended with the two components, modified polyethylene terephthalate obtained by copolymerizing a sulfonate compound is preferable because it has good compatibility with the polyetheresteramide R1 component. Here, a preferable sulfonate compound as a copolymerization component of the modified polyester is 5-sodium sulfoisophthalic acid,
5- (tetraalkyl) phosphonium sulfoisophthalic acid and ester derivatives thereof, sodium r-hydroxyethoxybenzenesulfonate, potassium 2,5-bis (hydroxyethoxy) benzenesulfonate and the like can be used. The copolymerization amount of the sulfonate compound is 0.1 with respect to the acid component in consideration of the compatibility with the polyether ester amide R1 and the physical properties of the obtained cotton fiber.
-7 mol% is preferable, and 0.5-5 mol% is more preferable.

Further, a part of the dicarboxylic acid component of the polyester R2 component is a dicarboxylic acid such as adipic acid or isophthalic acid and its ester derivative, r-oxybenzoic acid,
It may be replaced by an oxycarboxylic acid such as р-β-oxyethoxybenzoic acid and its ester derivative.

Further, a part of the glycol component is, for example,
It may be replaced with glycol such as 1,4-bis (β-oxyethoxy) benzene, bisglycol ether of bisphenol A, and polyalkylene glycol. Furthermore, pentaerythritol, trimethylolpropane,
A chain branching agent such as trimellitic acid or trimesic acid can also be used.

In addition, the polyester R2 component of the present invention includes sodium polyacrylate, poly-N-vinylpyrrolidone, polyacrylic acid and copolymers thereof, polymethacrylic acid and copolymers thereof, polyvinyl alcohol and copolymers thereof. A hygroscopic / water-absorbing substance such as a polymer, polyacramide and a copolymer thereof, a cross-linked polyethylene oxide polymer, and a general-purpose thermoplastic resin such as polyolefin and polyamide may be contained to such an extent that the object of the present invention is not impaired.

In addition, in addition to pigments such as titanium oxide and carbon black, various antioxidants, anti-coloring agents, light-proofing agents, antistatic agents, etc. may be added to the stuffed cotton fibers of the mattress, if necessary. Is also preferable.

In the wadding fiber of the present invention, the polyether ester amide R1 component is the main moisture absorbing component, and the combined amount of the polyether ester amide component must be 15 to 50% by weight. If it is less than 15% by weight, there is a problem that it is difficult to obtain sufficient feeling of use due to moisture absorption. 50
If it exceeds 5% by weight, the rigidity of the whole fiber will decrease, and it tends to cause the robustness of crimp and insufficient repulsion when compressed as a wadding, and at the same time, the structure due to asymmetric cooling during the wadding of the wadding fiber described below. It is difficult to give a sufficient difference. 3
It is difficult to obtain a sufficient three-dimensional crimp, and the polyetheresteramide component of the intermediate layer is likely to appear on the fiber surface, which causes sticking between the single fibers and deteriorates the spinnability during the production of short fibers. There is a problem that the amount of high components increases and the cost increases.

The stuffed cotton fiber of the mattress of the present invention is
It is necessary to determine the composite amount and the fiber morphology of the polyether ester amide component so that the moisture absorption rate after standing in an atmosphere of 30 ° C. × 90% RH for 24 hours becomes 2% or more. If it is less than 2%, there is a problem that the desired comfort cannot be obtained due to moisture absorption. For higher comfort, use a moisture absorption rate of 4%
It is more preferable to make the above. The upper limit of the moisture absorption rate is not particularly limited, but according to the findings of the present inventors,
Generally, 30% is preferable from the viewpoint of not impairing the spinnability at the time of manufacturing the stuffed cotton fiber.

The padded cotton of the mattress of the present invention is a composite of polyether ester amide R1 component and polymer of polyester R2 component. The polyether ester amide R1 component is a hygroscopic component and generally deforms at low temperature. In terms of fiber structure, for example, as shown in FIG. 1 or FIG. 3, the structure in which the polyether ester amide R1 component is wrapped with the polyester R2 component polymer is used to improve the spinnability and the fiber structure stability during the production of stuffed cotton fiber. A good one is preferable. In addition, in order to increase the bulkiness of the stuffed cotton fiber by hollowing the fiber, or to perform three-dimensional crimping by performing an asymmetrical cooling treatment immediately below the spinneret during spinning of the stuffed cotton fiber to increase the bulkiness of the stuffed cotton fiber. Shows a structure in which the fiber cross section is made hollow by blending the polyether ester amide R1 component and the polyester R2 component as shown in FIG. 2, or the structure in which the polyether ester amide R1 component is wrapped with the polyester R2 component polymer as shown in FIG. Those hollowed out are preferred.

Further, as the stuffed cotton fibers of the mattress, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used. If it is thinner than 0.5 denier, the bulk of the aggregate required for stuffed cotton will be low,
The resilience to compression and the recovery of bulk also tend to decrease. If it is thicker than 30 denier, the texture tends to be coarse and hard. Further, if the fiber length is shorter than 10 mm, the entanglement between the fibers is deteriorated and the cotton breaks easily, and if it is longer than 100 mm, the fiber-opening property and the cotton-making property tend to be deteriorated. The crimp may be appropriately determined depending on the application to be used, but in order to improve the bulkiness, softness, resilience to compression and recovery, or cotton production, it is preferable to provide mechanical crimp. Asymmetric cooling treatment is applied during spinning, and fiber 1
It is more preferable that one piece is three-dimensionally crimped by giving a structural difference. The number of crimps is 3 to 10 peaks / 25 mm, and the crimping degree is 5
It is preferably 30%.

Further, in the mattress of the present invention, it is preferable to mix 30 to 70% by weight of the composite fiber A as a wrapping material of stuffed cotton, ordinary polyester fiber, and particularly 70 to 30% by weight of hollow fiber. By blending ordinary polyester fibers, the bulkiness is further enhanced, the water transfer property in the blended cotton aggregate is improved, and the feeling of use is improved. If the content of ordinary polyester fiber is less than 30% by weight, the effect of improving bulkiness may be reduced, and if it exceeds 70% by weight, the proportion of the composite fiber may be reduced and the use comfort due to moisture absorption may be insufficient.

The cross-sectional shape of the cotton wadding of the mattress of the present invention is not limited to a round shape, and it is more preferable that the cross-sectional shape is a polygonal shape or other irregular shape.

Furthermore, the hard cotton of the stuffed cotton of the mattress of the present invention is composed of the low melting point fiber B and the other fiber C, and the melting point of the low melting point fiber B is 20 lower than that of the other fiber C having the lowest melting point. It is preferable that the temperature is lower than 0 ° C., and the low melting point fibers B are bonded to each other and the low melting point fibers B are bonded to each other at a part of the intersections of the other fibers C.

The low melting point fiber B used in the present invention is a composite fiber, in which a polymer R3 having a low melting point is compounded on the surface side of the composite fiber and a polymer R4 is compounded on the inner side, and the melting point of the polymer R3 is higher than that of the polymer R4. It is preferably 20 ° C. or more lower and the weight ratio represented by R3 / R4 is in the range of 40/60 to 90/10. If the weight ratio of R3 is less than 40%, the thermal adhesion between the constituent fibers of the cotton may not be sufficiently obtained. On the other hand, the weight ratio of R3 may be 100% by weight. The low melting point fiber B is cut during use,
Since it may become a powder and cause dust generation, it is more preferable that the content be 90% by weight or less.

Examples of the polyester low melting point polymer R3 include, for example, polyolefins such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, ethylene vinyl acetate copolymer, or olefin copolymers, and polyhexamethylene terephthalate. ,
At least one kind of polymer selected from thermoplastic polymers such as polyesters such as polyhexamethylene butylene terephthalate and polyhexamethylene terephthalate isophthalate or copolymerized polyesters can be used. In this case, the polymer R4 is not particularly limited, and examples thereof include terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol as a main glycol component. A polyester such as butylene terephthalate or polyethylene 2,6-naphthalate can be used.

In addition to the low melting point fiber B, if necessary, R
In addition to pigments such as titanium oxide and carbon black other than 3 and R4, antioxidants, anti-coloring agents, light fastness agents, antistatic agents and the like may be added. Such a fiber B can be manufactured by a conventional composite spinning method.

As the low melting point fiber B, a short fiber having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm is preferably used from the viewpoints of thermal adhesiveness, softness imparting and elasticity. The low melting point fiber B in the hard cotton of the present invention is preferably 20 to 60% by weight. When the amount of the fiber B is less than 20% by weight, the number of heat bonding points on the fiber B is small and the morphological stability tends to decrease. If the amount of the fiber B exceeds 60% by weight, the softness and elasticity of the cotton tend to be deteriorated.

The solid cotton used in the present invention is, for example, a mixture of low melting point fiber B and ordinary polyester stuffed cotton, carded with a roller card, and the mixture cotton web is laminated on a molding machine and subsequently heated to form fibers B and to each other. A part of the intersections of B and other fibers C can be adhered to each other, and the cotton wool of the required density can be obtained by compressing and fixing and cooling it through the heater rollers.

Another object of the present invention is to provide a mattress that is easy to recycle. Common futons are made of cotton, which is excellent in touch, hygroscopicity, cotton wicking resistance, and pill resistance. In addition, embroidery threads for side cloths, side sewing threads, type and handling label, etc. Fibers with a different chemical composition than the wadding fibers are often used. Therefore,
When collecting and reusing, it is also possible to cut the side fabric and take out only the stuffed cotton fiber for reuse, but it is troublesome and a big obstacle. Therefore, in the present invention, from the viewpoint of a mattress that can be easily recycled, all of the quilted cotton of the futon, the side cloth, the side cloth sewing thread, and the accessories such as the type and the handling display label are polyester-based fibers or polyester-based resin products. It is preferable that it is composed of

Since the mattress of the present invention uses polyester fibers as the constituent fibers, any of material recycling, chemical recycling, thermal recycling and the like can be performed. From the viewpoint of ease of reuse and recycling effect, material recycling is preferable in which the recovered product is melt-pelletized, melt-spun, and reused.

[0042]

Next, the present invention will be described more specifically with reference to examples and comparative examples. The measuring methods of various characteristics described in the present invention are as follows.

(1) Moisture Absorption Rate The dry weight of the rolled cotton fiber of the mattress of the present invention is 30
It was determined by the following formula from the weight change after leaving it in a thermo-hygrostat for 24 hours under an atmosphere of ° C x 90% RH.

Moisture absorption rate (%) = [(weight after moisture absorption−weight in absolute dry) / weight in absolute dry] × 100 (2) Fineness It was measured according to the method of JIS L1015-7-51A.

(3) Average fiber length (cut length) JIS L1015A method (staple diagram method)
It measured according to.

(4) Number of crimps and degree of crimping The number of crimps and the degree of crimping are JIS L1015-7-12-
1 and the method of JIS L1015-7-12-2.

(5) Spinnability during spinning / drawing There were no problems such as yarn breakage during spinning / drawing, sticking, and stain on the spinneret, and a good spinnability (⊚) to a difficulty in spinning (x) were evaluated.

(6) Comfortability as a mattress The hygroscopic polyester-stuffed cotton fiber used in the present invention was carded with a roller card to fabricate a web into laminated cotton. Hard cotton is manufactured in the same way as hard cotton for mattresses that is generally manufactured, and the surface of this hard cotton is wrapped with cotton wrapping,
The quilt is laid on the polyester side sewn with polyester sewing threads. The comforter uses a commercially available cotton skin comforter, the pillow is packed with commercially available normal polyester chips, and the cotton summer pajamas are actually worn in a room controlled at a temperature of 27 ° C. and 70% RH. However, it was rated on a 7-point scale from comfortable (⊚) to extremely damp (x).

Examples 1 to 4 and Comparative Examples 1 to 3 As polyether ester amide R1, 340 parts of ε-caprolactam, 18 parts of terephthalic acid and a number average molecular weight of 10
100 parts of polyethylene glycol of No. 00, 0.1 part of Irganox 1330 (manufactured by Ciba Geigy) and 0.01 part of trimethyl phosphate were charged into a polymerization reaction vessel, and the mixture was heated and stirred at 240 ° C. for 1 hour under a nitrogen stream, and Add 0.1 part of antimony oxide, and under a temperature rising and depressurizing program, 250 ° C, 0.5 mmHg or less, 4
By carrying out the polymerization reaction for a time, the ratio of the N6 component becomes 4
A 5% by weight polyether ester amide block copolymer was obtained. The relative viscosity ηr at 25 ° C. of this orthochlorophenol solution (concentration 0.5 g / 100 ml) was 2.05. The moisture absorption rate of the polymer alone is 15.2
%Met. Using ordinary polyethylene terephthalate as the R1 and the polyester R2, a spinning temperature of 280
℃, the number of spinneret holes 24, take-up speed 1350m / min, to form a concentric structure with R1 as the core and R2 as the sheath as shown in FIG. 1, and subjected to the usual asymmetric cooling treatment directly below the spinneret, An undrawn yarn of stuffed cotton fiber was spun. Next, the unstretched yarn is combined with a tow denier of 100,000 denier after stretching, stretched at a draw ratio of 3.0 times and at a stretching bath temperature of 80 ° C., and mechanical crimping is given by a crimper to give a finishing oil agent. After cutting and cutting, set and dry with a heat setter at 145 ° C to obtain a composite fiber A with a fineness of about 6 denier and a cut length of 51 mm.
I got

The obtained composite fiber A was carded by applying it to a roller card, and a card web was laminated with a molding machine to make cotton.

On the other hand, as hard cotton, first, R4 of the low-melting fiber B is a normal polyethylene terephthalate having a melting point of 255 ° C., and R3 is a polyethylene terephthalate type polyester having a melting point of 110 ° C. copolymerized with 40 mol% of isophthalic acid. Spinning temperature 285 ° C, take-up speed 1350m
/ Min, discharge rate 18.11 g / min, R4 having a weight ratio represented by R3 / R4 of 60/40 as a core part, and R3 as a sheath part of concentric circular low melting point composite fiber B undrawn yarn Was spun. This undrawn yarn was drawn at a draw ratio of 3.0 and a drawing bath temperature of 80.
The film was stretched at 0 ° C. and mechanically crimped with a crimper. further,
After drying with a heat setter at 70 ° C, apply a finishing oil agent, cut into a cut length of 51 mm, and have a fineness of about 4 denier,
A low melting point conjugate fiber B having a melting point of the surface layer of about 110 ° C. was obtained.

Next, as another fiber C, the melting point is 25.
An unstretched yarn was spun with a normal polyethylene terephthalate at 5 ° C. in a pellet state, a spinning temperature of 280 ° C., a spinneret hole number of 24, and a take-up speed of 1350 m / min to give a circular cross-section structure. Then, the undrawn yarn is combined with a tow denier of 100,000 denier after drawing, and a draw ratio of 3.
After drawing 0 times and drawing bath temperature of 80 ° C and applying mechanical crimping with a crimper, it is cut to a cut length of 51 mm and heat-treated at 175 ° C to have a fineness of about 18 denier and a crimping number of 7.6 threads / 2.
Other fiber C having 5 mm and a crimping degree of 16.1% was obtained.

The fibers B and C are mixed and carded with a roller card, and the mixed cotton web is continuously heated while being laminated with a molding machine, compressed and fixed through a heater roller and cooled to a density of 0.03 g / cm. Hard cotton of ³ .

On the other hand, as the mattress side material, a plain weave woven fabric using anti-pill type polyester staple (2 denier, 51 mm) and a flower pattern printed fabric were used, and the sewing thread was made of high strength type polyester filament yarn 3 It was used as a mattress side mat with twisted yarn. Polyester non-woven fabric was used for the type and handling label.

Further, the fiber A was squeezed around 2 kg of the hard cotton.
2 kg of the laminated web-wound cotton of (1) was wound and the side of the mattress was packed to form a mattress.

In Table 1, the properties of the cotton wraps obtained by changing only the composite ratio of the polyether ester amide R1 and the normal polyethylene terephthalate R2, the spinning properties at the time of spinning / drawing the cotton and the hard cottons are wrapped with these wraps. The results of comfort evaluation of the mattress obtained in the above are shown.

The wound cotton fibers of Examples 1 to 4 had a polyether ester amide R1 composite ratio of 15 to 50% by weight, exhibited crimping due to asymmetric cooling, and had good spinnability during spinning. Moreover, the moisture absorption rate of only the cotton fiber is 2.2.
At 7.7%, comfort was good when used as a mattress.

On the other hand, in Comparative Example 1, the polyether ester amide R1 was not used and only ordinary polyester was produced, and there is no problem in the spinnability during spinning and drawing,
Since the crimp was not enough and the mattress was not soft enough, and the moisture absorption rate was low, when it was used as a mattress, it felt stuffy and was difficult to sleep. In Comparative Example 2, the composite ratio of the polyether ester amide R1 was 14% by weight, the crimp due to asymmetric cooling was relatively exhibited, and the spinnability during spinning was also good, but the moisture absorption rate was 1.9% and the moisture absorption was Because of the low rate, when I used it as a mattress, I felt damp and had difficulty sleeping. Further, in Comparative Example 3, the polyether ester amide R1 has a composite ratio of 52% by weight.
At this time, crimping due to asymmetrical cooling is often expressed, and the moisture absorption rate is 8.
When it was 0%, it was comfortable to use as a mattress, but yarn breakage during spinning and sticking between fibers were observed, resulting in poor spinnability.

The futons of Examples 1 to 4 were used for each of the five levels 6
It is used for a month, and the side fabric is defibrated with an anti-fluffing machine, and the defibrated fibers are melted and pelletized, melt-spun and stretched again,
It was a 6-denier, 51 mm polyester staple. The obtained staples were gray colored polyester staples, which were slightly lower in strength and lower in moisture absorption rate than ordinary commercially available polyester staples, but were sufficiently usable as general cotton stuffing. .

[0060]

[Table 1] [Example 5] As another fiber C, ordinary polyethylene terephthalate having a melting point of 255 ° C was pelletized,
At a spinning temperature of 280 ° C. and at a take-up speed of 1350 m / min, an undrawn yarn having a circular hollow cross-section structure and subjected to asymmetric cooling treatment directly below the spinneret was spun. Next, this undrawn yarn was drawn at a draw ratio of 3.0 times at a drawing bath temperature of 80 ° C., mechanical crimped by a crimper, and then cut into a cut length of 51 mm to 1
Heat treated at 75 ℃, fineness about 6 denier, crimp number 7.4
Other fiber C having a crest / 25 mm and a crimping degree of 26.2% was obtained. A mattress was produced in the same manner as in Example 4 except that 50% by weight of the other fiber C and 50% by mass of the composite fiber A of Example 4 were mixed, and the comfort when used as the mattress was evaluated. The average moisture absorption rate of the entire cotton wrap was 4.0%, and the comfort feeling when used as a mattress was good.

Further, the side fabric was defibrated by a fluffing machine in the same manner as in Example 4, and the defibrated fibers were melt-pelletized, melt-spun and stretched again to obtain 6-denier, 51 mm polyester staple. The obtained staples were gray colored polyester staples, which were slightly lower in strength and lower in moisture absorption rate than ordinary commercially available polyester staples, but were sufficiently usable as general cotton stuffing. . Example 6 The polyether ester amide R1 obtained in Example 1 and normal polyethylene terephthalate R2 having a melting point of 255 ° C. were made into pellets, respectively, and R1 = 30% by weight and R2 = 70% by weight were blended, and the spinning temperature was 280.
An undrawn yarn of blended cotton fiber was spun by making a hollow cross-section structure having a hollow ratio of 30% at a temperature of 1350 m / min and a normal asymmetric cooling treatment just below the spinneret.

Then, the undrawn yarn is drawn at a draw ratio of 3.0 times,
Stretching at a drawing bath temperature of 80 ° C, applying mechanical crimping with a crimper, applying a finishing oil, cutting, setting and drying with a heat setter at 145 ° C, and a composite fiber A with a fineness of about 6 denier and a cut length of 64 mm. Got

A comforter was manufactured in the same manner as in Example 1 except that this composite fiber A was used as the cotton fiber, and the comfort when using the comforter was evaluated. The moisture absorption rate of the cotton wrap was 4.8%, and the comfort feeling when used as a mattress was good.

Also, the futon of this Example 6 was used for 6 months, and the side fabric was defibrated by a fluffing machine in the same manner as in Example 1, and the defibrated fibers were melted and pelletized, and the same as in Example 1. Melt spinning and drawing again, 6 denier, 61 mm
Made of polyester staple. The obtained staple was a gray staple and was a hollow staple in which polyetheresteramide R1 and polyester R2 were blended, and although it had a slightly low moisture absorption rate, it could be used as a polyester wadding fiber.

Example 7 The polyether ester amide R1 obtained in Example 1 and ordinary polyethylene terephthalate R2 having a melting point of 255 ° C. were each pelletized, and R
1 to the hollow cross section 1 as shown in FIG. 3, and R2 to the outer 2 and inner 2
Used for the outer 2 / inner 2/1 weight ratio 35/35/3
0, a spinning temperature of 280 ° C., a take-up speed of 1350 m / min, a hollow cross-section structure with a hollow ratio of 28%, and an ordinary asymmetric cooling treatment was performed directly below the spinneret to form an undrawn yarn of the triple-composite hollow composite fiber A. Was spun.

Then, the undrawn yarn is drawn at a draw ratio of 3.0 times,
Stretching at a drawing bath temperature of 80 ° C, applying mechanical crimping with a crimper, applying a finishing oil agent, cutting, setting with a 145 ° C heat setter and drying, and a fineness of about 7 denier, composite fiber A with a cut length of 51 mm Got

50% by weight of the obtained conjugate fiber A and 50% by weight of the other fibers C produced in Example 5 were mixed to obtain a cotton wool.

In addition, Example 1 was used except that 30% by weight of the low melting point fiber of Example 1, 40% by weight of the other fiber C of Example 1 and 30% by weight of the composite fiber A of Example 7 were used in the production of cotton.
A mattress was manufactured in the same manner as in Example 1 and the comfort when used as a mattress was evaluated. The average moisture absorption rate of the cotton wrap was 2.5%, but the hygroscopic composite fiber A was also mixed with the solid cotton, and the comfortable feeling when used as a mattress was good.

Further, the futon of this Example 7 was used for 6 months, and the side fabric was defibrated with a fluffing machine in the same manner as in Example 1, and the defibrated fibers were melted and pelletized, and the same as in Example 1. Melt spinning and drawing again, 6 denier, 61 mm
Made of polyester staple. The obtained staple was a gray staple and was a hollow staple obtained by blending polyetheresteramide R1 and polyester R2, and although it had a slightly low moisture absorption rate, it could be used as a polyester wadding fiber.

[0070]

According to the mattress of the present invention, it is possible to provide a mattress that has good yarn-forming properties when producing stuffed cotton fibers, has a comfortable feeling as a mattress, and is easy to recycle.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view showing a model of an example of a fiber for wadding used in the present invention.

FIG. 2 is a schematic cross-sectional view schematically showing another example of the fiber for wadding used in the present invention.

FIG. 3 is a schematic cross-sectional view schematically showing another example of the fiber for wadding used in the present invention as a model.

[Explanation of symbols]

 1: Polyether ester amide R1 2: Polyester R2

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display area // D01F 8/12 D01F 8/12 Z

Claims (9)

[Claims] 1. A quilt comprising a cotton wrap of polyester fiber and a hard cotton of polyester fiber, wherein the cot is at least polyetheresteramide R.
15-50% by weight of one component and 5 of polyester R2 component
0 to 15% by weight of composite fiber A, and 30
Moisture absorption rate after standing in an atmosphere of ℃ × 90% RH for 24 hours is 2% or more, and the hard cotton is at least a part between the low melting point fibers B and between the low melting point fibers B and the other fibers C. Mattress that is adhered to. 2. The mattress according to claim 1, wherein the side material, the sewing thread and the accessories of the mattress are all made of polyester fibers. 3. The mattress according to claim 1 or 2, wherein the melting point of the low melting point fiber B is 20 ° C. or more lower than the lowest melting point fiber among the other fibers C constituting the hard cotton. 4. The composite fiber A of the wound cotton of the mattress is a composite fiber having a polyether ester amide R1 component as a core part and a polyester R2 component as a sheath part. Bed linen described in. 5. The mattress according to any one of claims 1 to 3, wherein the composite fiber A of the cotton of the mattress is a hollow fiber obtained by blending the polyether ester amide R1 component and the polyester R2 component. . 6. A composite fiber A of rolled cotton of a mattress is a three-layer composite hollow fiber in which an intermediate layer composed of a polyetheresteramide R1 component is composited between an outer layer composed of a polyester R2 component and an inner layer. Claims 1 to 1 characterized
The mattress according to any one of 3 above. 7. The mattress according to any one of claims 1 to 6, wherein the fibers constituting the stuffed cotton of the mattress have a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm. 8. The staple fibers of the mattress are short fibers having a three-dimensional crimp generated by asymmetric cooling, having a crimp number of at least 3 peaks / 25 mm and a crimp degree of at least 5%. The mattress according to any one of claims 1 to 7, characterized in that. 9. A wadding of a cotton cot is composed of 3 composite fibers A of a polyether ester amide R1 component and a polyester R2 component.
0 to 70% by weight, normal polyester fiber 70 to 30
The mattress according to any one of claims 1 to 8, wherein the mattress comprises a blended weight of cotton.